High voltage miniaturized relay

ABSTRACT

A high voltage relay is provided in which the operating components of the relay are enclosed in a sealed envelope which may be evacuated. The relay to be described is a miniaturized high voltage relay capable, for example, of operating at voltages up to 5 kilo-volts, and in conjunction with relatively high frequencies. The envelope of the relay is composed of ceramic, and the relay is capable of efficient operation in wide extremes of ambient temperatures. The relay includes a linearly movable contact which makes connection with a fixed common electrical terminal through a resilient diaphragm which is constructed to permit free linear reciprocal movement of the movable contact and yet maintain a positive electric current to the common terminal.

United States Patent 1151 3,699,486 De Lucia 1 Oct. 17, 1972 [54] HIGH VOLTAGE MINIATURIZED 2,993,970 7/1961 Yanagisawa ..200/l44 B RELAY 3,154,655 10/1964 Hawkins ..335/131 [72] Inventor: victor E. De Lucia, Los Angeles, 3,119,940 l/l964 Pett1t et al. ..355/229 Cahf Primary Examinerl-Iarold Broome [73] Assignee: Torr Laboratories, Inc., Los An- Attorney-Jessup & Beecher geles, Calif. 57 ABSTR T [22] Filed: Aug. 2, 1971 ill b l l fl d h h h 1g vo tage re ay 1s prov1 e 1n w ie t e operat- [211 168,009 ing components of the relay are enclosed in a sealed envelope which may be evacuated. The relay to be 52 us. c1. .335/131, 200/144, 335/170, described is a miniaturized g voltage relay capable,

3 5 29 for example, of operating at voltages up to 5 kilo- 51 1.11.131. ..H01h 51/10 volts, and in conjunction with relatively high frequen- [58] Field of Search ..335/170, 179, 154, 229, 131; cies- The envelope of the relay is l of ceram- 200/166 BA 166 BB 144 B 16 A ic, and the relay is capable of efficient operation in wide extremes of ambient temperatures. The relay in- [56] References Cited cludes a linearly movable contact which makes connection with a fixed common electrical terminal UNITED STATES PATENTS through a resilient diaphragm which is constructed to permit free linear reciprocal movement of the mova- 3i0221450 2/1962 Chase Jr "335/229 ble contact and yet maintain a positive electric current 3,070,730 12/1962 Gray et al. ..335/229 to the common terminaL 3,331,040 7/1967 Woodhead ..335/154 3,017,479 l/ 1962 Jennings ..200/l6 A 8 Claims, 4 Drawing Figures 7: I'M/I7! 1 7:

70-7 1 1'0 r l 10 7 2 2 arm/2rd 2 r 6 20 3 743 12 1- 1Z-// 7J/fi/apfi a m-F/ lvzrrm'w/ 1k; 22 r; f

224. 14 2560a I01) 141/ 25 i2 /-drdj 4"!0/(119-34 7 (org) 0/7 Jig Z 9 I 42- $0, I; 30 (Ira/1 Hour/r71 BACKGROUND OF THE INVENTION Vacuum relays have achieved wide utility in the relay art, in that deterioration of the relay contacts is reduced to a minimum. This is because the absence of gases in the evacuated envelope of the relay obviates the formation of contact-eroding oxides to a material extent.

However, problems have been encountered in the prior art vacuum relays, including the problem of vaporized metal which is released by ion bombardment in the contact area and which has a tendency to weld the contacts together during the operation of the relay. Also, a problem has long existed in providing an adequate connection between the movable contact of the relay and the terminal connection to that contact, which connection is positive and continuous and not subject to arcing with a tendency to circuit discontinuity.

The relay of the present invention is constructed in an improved and simplified manner, and it has a reciprocally moving contact which establishes selective positive contact with the fixed contacts of the relay, and which also is connected to an improved resilient diaphragm to a common electrical terminal of the relay.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a sectional representation of a relay constructed in accordance with one embodiment of the invention;

FIG. 2 is a cross-section, essentially along the line 2--2 of FIG. 1;

FIG. 3 is a cross-section, essentially along the line 33 of FIG. 1, on an enlarged scale, and illustrating a diaphragm element which is incorporated into the relay of FIG. 1; and

FIG. 4 is a side section of a relay representing a second embodiment of the invention, the relay of FIG. 4 incorporating a permanent magnet so as to constitute a latching relay.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS The relay of FIG. 1 includes a stack of cylindricalshaped members 10, 12 and 14 of electrically insulating material, such as ceramic, which are mounted in coaxial relationship with one another to constitute the envelope of the relay. The ends of each of the ceramic cylinders 10, 12 and 14 are metallized. A first annularshaped electrically conductive terminal member 16 is brazed to the upper end of the cylindrical member 10, and a cap 18 is brazed over the top of the annular conductive terminal 16 to constitute an enclosing cover for the envelope. The cap 18 may be formed of nickel, or other appropriate material. The annular member 16 has an elongated portion 16a which extends out one side of the assembly to permit an electric connection to be made to the relay. The members 10, 12 and 14 may, for example, be made of beryllium oxide which is a good electrical insulator, and yet is a good heat conductor for efficient heat transfer from the active elements of the relay.

A second annular terminal member 20 is brazed to the ends of the cylindrical members and 12, and it includes an elongated integral portion a which extends out from the side of the assembly, as shown, and which also forms a terminal connection for the relay. A third annular terminal member 22 is brazed to the ends of the ceramic members 12 and 14, and it has an elongated portion 22a which, likewise, serves as an electric terminal for the relay. The members 16, 20 and 22, and their integral portions 16a, 20a and 22a may be formed, for example, of berylium copper, or other appropriate electrically conductive material.

The lower end of the envelope formed by the ceramic members 10, 12 and 14 is affixed to a ring 26 formed of magnetizable material such as iron. The ring 26 is sealed to the lower end of the cylindrical member 14 by an appropriate material 28 composed, for example, of Kovar, which serves to provide an adequate seal between the ring 26 and the ceramic member 14 for wide ranges of temperature.

A tubular housing 30 which is formed of iron, or other suitable magnetizable material is brazed or otherwise attached to the ring 28, the housing 30 extending coaxially with the body assembly of the ceramic members 10, 12 and 14, on the opposite side of the ring 26. A mounting flange 32 is brazed or otherwise attached to the housing 30, as shown.

An inner tubular member 32 composed of a nonmagnetic material such as monel metal is supported coaxially within the housing 30, and extends into the ring 26. A movable armature plunger 34 is slidable in the tubular member 32, the plunger 34 being formed, for example, of magnetizable material such as iron. A ceramic rod 38 which is affixed to a support bridge 40 extending across the top of the armature 34. The armature 34 is shown as hollow so as to provide low inertia for the relay.

An iron core 41 is provided in the housing 30, and a spring 42 is housed in a cavity in the iron core, the spring bearing against the underside of the armature 34 so as to bias the armature upwardly in FIG. 1. The core 41 is held in place by means of a screw 48 extending, for example, through the bottom of the housing 30, and threaded into the core 41.

An electric coil 52 is wound in the housing 30 around the core 41, and when the coil 52 is energized, the armature 34 is drawn down into the housing 30 against the end of the core 41 and against the bias of the spring 42. When the coil is de-energized, on the other hand, the spring 42 moves the armature back to its illustrated position in FIG. 1. Electrical connection is made to the coil 52 through a pair of terminals 56 and 58 which extend through bushings 60 and 62 in the bottom of the housing 30.

An electrically conductive rod extends upwardly from the ceramic rod 38 and through the various annular terminal members 16, 20 and 22. A first electrical contact 72 is welded or otherwise affixed to the rod 70 at the upper end thereof, the contact 22 being normally spaced from the annular contact 16. However, when the relay is energized, the downward movement of the armature 34 causes the contact 72 to engage the annular contact 16 and establish electrical connection thereto from the conductive rod 70.

A second contact 74 (FIG. 2), of the same shape as the contact 72, is welded or otherwise affixed to the rod 70, and the contact 74 normally makes electrical contact with the underside of the contact 20. However, when the relay is energized, the downward movement of the armature 34 and rod 70 causes the contact 74 to move away from the contact 20. A diaphragm 78 is also attached to the rod 70, and is crimped to the annular contact 22 by three lugs 22b. The. diaphragm 78 is shown in an enlarged form in FIG. 3. The diaphragm is composed, for example, of a resilient material such as berylium copper, and it has the illustrated configuration in FIG. 2, so that when its central portion is attached to the rod 70, and its peripheral edge is attached to the terminal 22, free reciprocal movement of the rod 70 in a vertical linear direction is permitted, while maintaining a positive electrical connection with the terminal contact 22. The diaphragm 78 is formed, for

example, by photo-etching techniques.

Therefore, the relay illustrated in FIG. 1 operates to establish an electric connection between the common terminal C formed by the protruding portion 22a of the terminal contact 22 and the terminal B formed by the protruding portion 20a of the terminal 20, when the relay is de-energized; and it establishes electrical contact between the terminal C and the terminal A formed by the protruding portion 16a of the terminal contact 16, when the relay is energized. The contact 74 has the form shown in FIG. 2, so that during assembly it may be turned and drawn down into the envelope through the contact 20 to be disposed below the contact 20, as shown in FIG. 1. The contact 74 is then turned back so that it will engage the ears 20b of the contact 20 (FIG. 2) when the armature moves upwardly as the relay is de-energized.

The structure shown in FIG. 1 is a small, sturdy and rugged unit, and one which may operate at relatively high voltages, as described above, and in conjunction with high electrical frequencies. Also, the relay unit shown in FIG. 1 is capable of operation through wide ranges of ambient temperature.

The relay of FIG. 4 is generally similar to the relay of FIG. 1, and like elements have been designated by the same numerals. A significant difference between the relay of FIG. 4 and the relay of FIG. 1 is that the relay of FIG. 4 incorporates a radially magnetized permanent magnet member 100 so as to constitute a latching relay. The magnet 100 is formed, for example, of barium ferrite. In the latter structure, the permanent magnet 100 is mounted in the housing 30 in coaxial relationship with a first coil 52a and a second coil 52b as an injection molded sub-assembly. The coil 52a, when energized, draws the armature 34a down against the end of a lower core section 40a, and the armature remains in that position due to the attraction of the permanent magnet 100, even after the coil 52a has been de-energized. Then, to return the relay to its illustrated position, the coil 52b is energized which draws the armature up and away from the core 40a, to the illustrated position against an upper core section 40b, the .relay maintaining the illustrated position after the coil 52b has been de-energized, and until the coil 52a has again been energized. The armature 34a may be chromium coated and oxidized to prevent cold welding thereof with the upper and lower core sections.

In the construction of the relays described above, the cap 18 is brazed to the contact 16 as a final operation, and the relay is evacuated through holes in the depressed central section of the cap. The holes are then sealed by placing a pellet of copper/silver alloy, for example, in the depressed central section of the cap and melting the pellet by a high frequency electric current.

The invention provides, therefore, an improved miniaturized vacuum relay which has a strong and rugged construction, in which all its contacts are insulated from one another and from the housing, and which is capable of making and breaking high electrical potentials at high electrical frequencies. The relay also has the feature of operating through wide ranges of ambient temperatures.

While particular embodiments of the invention have been shown and described, modifications may be made, and it is intended to cover all modifications in the following claims which come within the spirit and scope of the invention.

What is claimed is:

1. A relay including: a housing; a plurality of annular contact members affixed to said housing at spaced positions therein; a movable element for the. relay including an electrically conductive rod extending coaxially within said annular contact members; solenoid means attached to one end of said housing for selectively moving said rod in a rectilinear reciprocal manner between a. first position and a second position with respect to said annular contacts; a resilient diaphragm composed of electrically conductive material attached to said rod and to one of said annular contacts and electrically 2. The relay defined in claim 1, in which said resilient diaphragm has a photo-etched pattern extending therethrough.

3. The relay defined in claim 1, in which said housing is formed of a stack of coaxially positioned open-ended cylindrical-shaped electrically insulating members separated by said annular contact members.

4. The relay defined in claim 3, in which said cylindrical-shaped members are ceramic.

5. The relay defined in claim 1, in which said solenoid means includes first and second electrical coils and a radially magnetized tubular permanent magnet interposed therebetween in coaxial relationship therewith; and a permanent magnet for latching said relay in each of the aforesaid first and second positions of said rod.

6. The relay defined in claim 5, in which said solenoid includes first and second magnetic core sections spaced axially from one another and disposed within said first and second coils, respectively; and in which said movable element includes a magnetic armature movable axially between said first and second core sections.

7. The relay defined in claim 1, in which said movable element includes a plunger formed of magnetizable material and received in said solenoid means, and a ceramic rod mounting said conductive rod on said plunger.

8. The relay defined in claim 3, in which said annular contacts each have an integral elongated portion protruding radially out from the external surface of said housing.

a: a: S 

1. A relay including: a housing; a plurality of annular contact members affixed to said housing at spaced positions therein; a movable element for the relay including an electrically conductive rod extending coaxially within said annular contact members; solenoid means attached to one end of said housing for selectively moving said rod in a rectilinear reciprocal manner between a first position and a second position with respect to said annular contacts; a resilient diaphragm composed of electrically conductive material attached to said rod and to one of said annular contacts and electrically connecting said rod to said one of said annular contacts, said diaphragm lying in a plane perpendicular to the axis of said rod; and at least one movable contact affixed to said rod for selective engagement with a further one of said annular contacts as said rod is moved between its first and second positions.
 2. The relay defined in claim 1, in which said resilient diaphragm has a photo-etched pattern extending therethrough.
 3. The relay defined in claim 1, in which said housing is formed of a stack of coaxially positioned open-ended cylindrical-shaped electrically insulating members separated by said annular contact members.
 4. The relay defined in claim 3, in which said cylindrical-shaped members are ceramic.
 5. The relay defined in claim 1, in which said solenoid means includes first and second electrical coils and a radially magnetized tubular permanent magnet interposed therebetween in coaxial relationship therewith; and a permanent magnet for latching said relay in each of the aforesaid first and second positions of said rod.
 6. The relay defined in claim 5, in which said solenoid includes first and second magnetic core sections spaced axially from one another and disposed within said first and second coils, respectively; and in which said movable element includes a magnetic armature movable axially between said first and second core sections.
 7. The relay defined in claim 1, in which said movable element includes a plunger formed of magnetizable material and received in said solenoid means, and a ceramic rod mounting said conductive rod on said plunger.
 8. The relay defined in claim 3, in which said annular contacts each have an integral elongated portion protruding radially out from the external surface of said housing. 